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1. VERTICAL MILL INSTALLATION INSTRUCTIONS


Machine footprints and operating dimensions are available in the brochure and the anchoring addendum

GENERAL REQUIREMENTS
Operating Temperature Range 41F to 104F (5 to 40C) Storage Temperature Range -4F to 158F (-20 to 70C) Ambient Humidity: 20% 95% relative humidity, non-condensing Altitude: 0-6000 ft. (Do not operate machine in explosive atmospheres (explosive vapors and /or particulate matter)

E LECTRICITY R EQUIREMENTS

IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE WIRING MACHINES.


ALL MACHINES REQUIRE: Line voltage that does not fluctuate more than 5% VS / VR Series: Three-phase, 50 or 60Hz power supply VF / VM / MDC-500 Series: AC input power is three phase Delta or Wye power, except that the power source must be grounded (e.g. leg or center leg for delta, neutral for Wye) Frequency range of 47-66 Hz Harmonic distortion not to exceed 10% of the total RMS voltage 20-15 HP System
STANDARD VF, and 10K

Power Supply 1 Haas Circuit Breaker If service run from elec. panel is less than 100' use: If service run from elec. panel is more than 100' use: 40-30 HP System Power Supply1 Haas Circuit Breaker If service run from elec.panel is less than 100' use: If service run from elec. panel is more than 100' use: 40-30 HP System VS Series Power Supply Haas Circuit Breaker If service run from ele.panel is less than 100' use: If service run from ele. panel is more than 100' use:

Voltage Requirements (195-260V ) 50 AMP 40 AMP 8 GA. WIRE 6 GA. WIRE Voltage Requirements
(195-260V)

High-Voltage Requirements
(354-488V)

25 AMP 20 AMP 12 GA. WIRE 10 GA. WIRE High-Voltage Requirements2


(354-488V)

50 TAPER, HT10K(40T), VM, SS mills

100 AMP 80 AMP 4 GA. WIRE 2 GA. WIRE Voltage Requirements


(195-260V)

50 AMP 40 AMP 8 GA. WIRE 6 GA. WIRE High-Voltage Requirements


(354-488V)

125 AMP 100 AMP 2 GA. WIRE 0 GA. WIRE

Must use an external transformer

Reference Manual June 2007 (Vertical)

Installation

WARNING!
A separate earth ground wire of the same conductor size as the input power is required to be connected to the chassis of the machine. This ground wire is required for operator safety and for proper operation. This ground must be supplied from the main plant ground at the service entrance, and should be routed in the same conduit as the input power to the machine. A local cold water pipe or ground rod adjacent to the machine cannot be used for this purpose. Input power to the machine must be grounded. For wye power, the neutral must be grounded. For delta power, a central leg ground or one leg ground should be used. The machine will not function properly on ungrounded power. (This is not a factor with the External 480V Option.) The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond an acceptable limit. The machine may function properly, yet may not deliver the advertised power. This is noticed more often when using phase converters. A phase converter should only be used if all other methods cannot be used. The maximum leg-to-leg or leg-to-ground voltage should not exceed 260 volts, or 504 volts for high-voltage machines with the Internal High Voltage Option.
1

The current requirements shown in the table reflect the circuit breaker size internal to the machine. This breaker has an extremely slow trip time. It may be necessary to size the external service breaker up by 2025%, as indicated by power supply, for proper operation.
2

The high-voltage requirements shown reflect the Internal 400V configuration which is standard on European machines. Domestic and all other users must use the External 480V option.

AIR REQUIREMENTS

Machine Type
40-Taper VF-1 through VF-11, VM 50-Taper VF-1 through VF-11 VR, VS and MDC Series

Main Air Regulator


85psi 85psi 85psi

Input Air Line Hose Size


3/8 1/2 1/2

The VF, VM and VS series machines requires a minimum of 100 psi at 4 scfm (VR-11 requires a minimum of 100 PSI at 9scfm) at the input to the pressure regulator on the back of the machine. This should be supplied by at least a two-horsepower compressor, with a minimum 20-gallon tank, that turns on when the pressure drops to 100 psi.
NOTE: Add 2 scfm to the above minimum air requirements if the operator will be using the air nozzle during pneumatic operations.

The recommended method of attaching the air hose is to the barb fitting at the back of the machine with a hose clamp. If a quick coupler is desired, use a 3/8" for 40 taper machines, or a 1/2" for 50 taper machines and machines with the side mount tool changer option. Excessive oil and water in the air supply will cause the machine to malfunction. The air filter/regulator has an automatic bowl dump that should be empty before starting the machine. This must be checked for proper operation monthly. Also, excessive contaminants in the air line may clog the dump valve and cause oil and/or water to pass into the machine.
NOTE: The nipple between the air filter/regulator and the oil lubricator reservoir tank is for the optional rotary table. DO NOT use this as a connection for an auxiliary air line. Auxiliary connections should be made on the left side of the air filter/ regulator.

WARNING!
WHEN THE MACHINE IS OPERATING AND THE PRESSURE GAUGE (ON THE MACHINE REGULATOR) DROPS BY MORE THAN 10 PSI DURING TOOL CHANGES, INSUFFICIENT AIR IS BEING SUPPLIED TO THE MACHINE.

Reference Manual June 2007 (Vertical)

Installation

I NSTALLATION T OOLS REQUIRED


Precision bubble level (0.0005 inch per 10") 1 1/8" hex wrench or ratchet 1 1/2" wrench Allen Wrenches (VR models) 12 Adjustable Wrench Forklift with the following specifications:
V F -1
Mach in e Weig h t * F o rk L e n g t h 7,100 8'

Test indicator (0.0005) Two 3/4" hex wrenches (open-end/box and ratchet) Claw hammer (VR models) 9/16 hex wrench

V F -2
8,000 8'

V F -3
12,500 8'

V F -4
13,300 8'

V F -5/40 V F -5/50
14,600 8' 16,100 8'

V F -6
21,000 8'

V F -7
23,000 8'

V F -8
24,000 8'

V F -9
25,000 8'

V F -1 0
28,000 8'

V F -11
29,400 8'

* The forklift must be capable of lifting at least this weight. VR: Forklift must be capable of lifting at least 35, 000 lbs, with forks at least 8 long. VS: Forklift must be capable of lifting more than 40,000 lbs, with forks at least 8 long by 6 wide.

MATERIALS REQUIRED
Wire and air hose or piping as specified in the Service Requirements section, A small amount of grease, Way lube for the lubricator (Vactra #2). Coolant (water-soluble synthetic, or cutting oil)

MOVING THE CRATE

CAUTION! THE VMC CRATE CAN ONLY BE MOVED WITH A FORKLIFT.

FORK

FORK

CAUTION! The fork positions are marked on the crate. (Also, note that there are three skids at each side of the pallet. The heavy part of the machine [the back] is positioned over the two skids that are closest together.) If the fork positions are ignored, the retaining bolts could be sheared off by the forks or the machine could tip over when it is picked up.

Reference Manual June 2007 (Vertical)

Installation

U NPACKING THE M ILL


1. Remove plastic cover.
CAUTION! Do not put pressure on the top of the machine as you remove the plastic.

2. Remove the coolant tank and the cleats that held it in place.
Set Screw

Shipping Bracket Coupler Assembly Pallet

Shock Mount Rubber Pad

All set screws are needed for installation

DO NOT DISCARD!

3. Unbolt the shipping brackets. 4. Remove the nuts on the leveling screws holding the shipping bracket to the base casting. Remove the shipping brackets. 5. Lift the machine off the pallet.

S ETTING IN P LACE
Keep in mind when moving the VF, VM, and VR models, much of its weight is concentrated in the column at the back. When lifting these mills from the side, it is important that the forks of the forklift be positioned as close to the back of the machine as possible without being on the pads.
CAUTION! Do not lift the machine any farther than necessary off the floor when moving it, and move as slowly and cautiously as possible. Dropping the machine, even from a height of a few inches, can cause injury, result in expensive repairs, and void the warranty.

VF 1-2 and VM-2: The only acceptable way to move this mill is to pick it up from the SIDE with a forklift. Follow the machine weight and fork length specifications described earlier. The forks must be set as far apart as possible without being on the pads. The forks must be positioned all the way to the back of the VMC and they must extend at least 3" past the far side of the machine base. Also, there must be about approximately 6" clearance between the forklift and the side of the machine. VF 3-11 and VR-11: Lift from the BACK of the machine with a forklift. Follow the machine weight and fork length specifications described earlier. There must be approximately 6" clearance between the forklift and the back of the machine. Attempting to move the machine any other way may void the warranty.
CAUTION! When lifting the machine with a forklift, be careful not to damage the sheet metal aprons with the forks.

Reference Manual June 2007 (Vertical)

Installation

MAX

OIL

LEVEL

BIJUR

MIN

OIL

LEVEL

3"

Min. 6" Clearance

VF 1 and 2

VF 3 through 11

1. Lift the machine clear of the pallet. 2. Thread the leveling screws through the casting until they extend about an inch out of the bottom of the machine. If a screw is excessively hard to turn, remove it, dress the threads in the hole with a 1-14 UNC tap, and inspect the screw. If the screw has dings, dress the threads with a 60o V file. (You must have good control over these screws because they are used to precision level the machine.) 3. Move the machine to where it will be located. Grease the dimple in each leveling pad and locate them under the leveling screws at the four corners. Then lower the machine.

4. Remove all banding and packing material around the control panel and the doors. 5. On the VF-6/8 and VR series, remove the pendant support. 6. Remove the control arm shipping brace. On the VF-3/4, swing the control arm into position and bolt it to the support on the top front of the machine enclosure. On the VF-6/8, swing the control arm to the proper position.

S ETTING THE M ACHINE IN P LACE (VS)


Ensure the anchoring preparations are in accordance with the anchoring instructions prior to setting the machine in place. 1. Prepare the table base for mating Remove the X-axis auger and auger trough Stone and clean thoroughly the mating flange surface. This is an extremely important step that must be well and properly done before the bases are moved into position with respect to each other. (Failure to properly prepare the surfaces and preserve their cleanliness may require separation of the main components for corrective action). Clean the holes in the table base. Ensure the air/electrical/oil lines and connectors are bundled and safely away from the mating surfaces.

Reference Manual June 2007 (Vertical)

Installation

2. Prepare the column base for mating Stone and clean thoroughly the mating flange surface. This is an extremely important step that must be well and properly done before the bases are moved into position with respect to each other. (Failure to properly prepare the surfaces and preserve their cleanliness may require separation of the main components for corrective action). Check the thread of each hole in the column base, ensure there is no damage. Ensure the air/electrical/oil lines and connectors are safely away from the mating surfaces. 3. Place the table base assembly in position. Rough level by measuring from the floor to the bottom of the base (very close to 2.5 inches). Each of the leveling screws and pads should be in place at this time and it is advisable to take the measurement at each leveling screw location for best results. This will ensure that the final leveling procedure will go more quickly and that the coolant tank will properly fit beneath the coolant discharge. Loosely screw the jam nuts onto the leveling screws.

2.5"

min

4. Place the column base assembly in position. When placing the column base in position with respect to the table base, it is important that the two mating flanges be as parallel as possible (vertically and horizontally). Be certain that each of the screws are actually engaged in the threads, and that when the column base is in place and the mating surfaces are in contact that each screw is free to rotate. Rough level by measuring from the floor to the bottom of the base (very close to 2.5 inches). Each of the leveling screws and pads should be in place at this time and it is advisable to take the measurement at each leveling screw location for best results. This will ensure that the final leveling procedure will go more quickly. After rough leveling, fully tighten the connecting screws to be sure the mating surfaces are in full contact, and then loosen them all approximately 3 full turns. Be certain that the connecting screws are still free to rotate (do not leave the connecting bolts tight at this time because the machine still must be final leveled and squared).
IN U NBLOCKIN ING THE M ACHINE

CAUTION!

Before unblocking machine ensure that counterbalance cylinder charging hose is attached to nitrogen tank and nitrogen tank is fully charged to 1250psi.

The counterbalance cylinders have been removed (for overhead clearance during shipping), and they must be reinstalled and recharged with dry nitrogen prior to enabling the Z-axis. The table is secured for shipping by means of blocks that are bolted to the table base. The column is secured for shipping by means of blocks that are bolted to the column base. The spindle head is secured for shipping and a cover has been placed over the Y-axis ballscrew and that cover must be removed.

Reference Manual June 2007 (Vertical)

Installation

Clamp Block Portion

Support Shipping Block Blocks for Portion

Counter Balance Tanks

Table

(2) Two-Piece Shipping Blocks A


Shipping (Stop) Block

(6) Shipping Blocks B


B

Shipping Blocks for Column

Y-axis Ballscrew Cover


Remove the cover from around the Y-axis ballscrew. There are two parts to the cover, a long section above the ballnut and a short section below the ballnut. Be certain to completely remove the cover from the ballscrew to prevent contamination after the Y-axis is later enabled. Inspect the ballscrew for any contamination that may have gotten through the dust cover during shipping and remove if necessary.

I NSTALLING THE HYDRAULIC COUNTERBALANCE SYSTEM


The hydraulic counterbalance system has been discharged of nitrogen (but contains the correct volume of fluid) and the hydraulic counterbalance cylinders have been removed from the column for overhead clearance in the shipping configuration. The hoses have been disconnected from the hydraulic cylinders and plugged. The hydraulic cylinders have been placed in the Y-axis auger trough for shipping. The two shoulder screws that secure each of the hydraulic cylinders to the top of the column have been stored by tightening them into the threads on the cylinder mounting surface on top of the column. The Z-axis has been disabled for reasons of safety when initially powering up the machine. 1. Remove the counterbalance cylinders from the auger trough and unwrap them. 2. Remove the flat washer and two jam nuts from the end of the rod. 3. Remove the two shoulder screws from the threads in the mounting surface on top of the column. 4. Remove the plug from the port of the cylinder and fully extend the cylinder rod. 5. Insert the counterbalance cylinder down through the top of the column and feed the end of the rod through the mating hole in the back of the spindle head. 6. Place the flat washer on the rod and thread both nuts onto the end of the rod. Before jamming the nuts together, be certain they are both high enough to allow the insertion of the cotter pin into the hole on the end of the cylinder rod. When the nuts are in place, jam the nuts together. Insert the cotter pin into the hole on the end of the rod. Repeat for the remaining hydraulic cylinder. 7. Insert and tighten the hydraulic hose fitting (use teflon tape on the fitting) in the port of the counterbalance cylinder. 8. Orient the cylinder so the hose will be away from the spindle head during operation and tighten the shoulder screws. 9. Remove the cap plug on the end of the hydraulic hose and connect it to the fitting (use teflon tape) that is now in the port of the cylinder.

Reference Manual June 2007 (Vertical)

Installation

10. Charge the counterbalance system using dry nitrogen to about 1300 psi (measure at the bottom of travel of the axis). Use all appropriate safety precautions and a supply bottle of adequate volume. Each bottle that is to be charged is a 90 cubic foot bottle. 11. Power up the machine and enable the Z-axis. 12. Check the operation of the Z-axis limit switch in diagnostics 13. Zero return the Z-axis only. The final pressure of the system at the top of travel should be slightly more than 1250 psi. After the axis has established zero, E-stop and note whether the axis has a tendency to slowly fall. This should be monitored in the position page of the display as well as a visual determination. If the axis falls at all, the counterbalance pressure should be slightly increased until the head cannot move downward from the top of travel in a servo off condition. Take care not to overcharge the system, an overcharge could cause the spindle head to move upward when in an E-stop condition at the bottom of travel.

U NBLOCKING THE TABLE


The table is held in place for shipping by means of blocks that are screwed into the table base. There is one block on each end of the table. These blocks must be removed before normal operation of the X-axis is possible. To access the shipping blocks, both X-axis way covers need to be fully retracted from the table. The Xaxis has been disabled in parameters for reasons of safety on power up of the machine.
Rubber Pad Clamp Block Support Block SHCS (9) Shipping Blocks

X-Axis Chip FHCS (4) Guard Way Cover

1. Disconnect both X-axis way covers from the table and fully retract the way covers. 2. Remove the front and rear X-axis chip guards to ease access to the underside of the table (if necessary). 3. Remove the blocks from the table base to prevent any inadvertent damage. WARNING!
BE CERTAIN THE MACHINE IS POWERED OFF WHEN CONNECTING OR DISCONNECTING SERVO MOTOR CABLES.

4. Uncoil the X-axis servo motor cable and connect to the motor. Do not attempt to route the cable to the final configuration at this time, but go directly from the control to the motor. This will provide power to the motor so the machine can be jogged in the X direction without zero return. 5. After the X-axis motor cable is connected, power the machine up and enable only the X-axis at this time. 6. Enable jog without zero return (setting 53) and move the table toward the home position taking extreme care that the X-axis cable does not get pinched between the table and any obstruction. Also be aware that there may be cables on the underside of the table that could be damaged while jogging in the shipping configuration.

Reference Manual June 2007 (Vertical)

Installation

7. When the table is moved just far enough to allow access to the two single piece shipping blocks, stop jogging the table and remove the two single piece shipping blocks completely from the table base. 8. Handle jog the table back to allow access to the support part of the two piece shipping blocks and remove them completely from the table base. 9. Continue jogging the X-axis far enough to allow access to the cable access hole. 10. Power the machine down. Disconnect the X-axis cable. 11. Route the table base cables and lines through the cable access hole. a) Route the X-axis motor and encoder cable and connect. b) Route the X-axis limit switch cable to the lube air panel. c) Route the oil line connector from the column base and connect with the oil line in the table base.
xis

X-A

X-axis motor cable is disconnected at the control.

Linear Scale Cable, Limit Switch and Lube Line Junction Disconnect at Interpolation box

12. Power up the machine and check the X-axis limit switch operation in diagnostics. 13. Zero return the X-axis 14. Check cable clearances under the table for the full X-axis travel and secure where necessary. 15. Reinstall the front and rear X-axis chip guards 16. Reinstall both X-axis way covers

UNBLOCKING THE COLUMN


The column is held in place for shipping by means of blocks that are screwed into the column base. There are two blocks in the front and two blocks in the rear of the column. These blocks must be removed before normal operation of the Y-axis is possible. To access the shipping blocks, both Y-axis way covers need to be fully retracted from the column. When the front Y-axis way cover is disconnected from the column, the lower Z-axis bellows will need to be properly supported. For that reason, the counterbalance must be charged prior to the removal of the shipping blocks in the column base, permitting the spindle head to be safely raised. The Y-axis has been disabled in parameters for reasons of safety on power up of the machine.

Reference Manual June 2007 (Vertical)

Installation

1. Disconnect the rear Y-axis way cover from the column and fully retract. 2. Remove the two shipping blocks and hardware completely from the column base. 3. Raise the spindle head to the full up position to allow the lower Z-axis bellows to be collapsed upward. 4. Disconnect the lower Z-axis bellows from the front Y-axis way cover and block up to permit access to the screws that attach the Y-axis way cover to the column. Disconnect the front Y-axis way cover from the column and fully retract taking care to not allow the Z-axis bellows to fall. When the way cover is retracted far enough, block the Z-axis bellows up and then continue to collapse the Y-axis way cover until it is fully retracted. 5. Enable the Y-axis in parameters but do not zero return 6. While ensuring the Z-axis bellows do not fall, handle jog (without zero return) the Y-axis toward the rear of the machine until access to the bolts holding the forward shipping blocks are accessible. 7. Block the Z-axis bellows up and remove the shipping blocks completely from the column base. 8. Check that the Y-axis cables are properly routed and the cable guide is securely attached to the base. 9. Check the operation of the Y-axis limit switch in diagnostics 10. Zero return the Y-axis.

SHIPPING BRACKET
1. Charge the hydraulic counterbalance system. See Installing the Hydraulic Counterbalance System section. 2. Power up the machine and raise the Z-axis to relieve pressure off of the shipping bracket. Do not home any axis at this time. 3. Remove the bolts securing the shipping bracket to the column base. 4. Clean the mating surface of the column base prior to mating the column to the table.

Reference Manual June 2007 (Vertical)

Installation

10

11x HHB

S HIPPING B OLTS - D OORS (VF/VM/VR)


Remove and discard shipping bolt from the inside of both doors

Door DOOR SECURED Shoulder Screw Removed

=
UNSECURED

I NITIAL SETUP
WARNING!
AT THIS POINT, THERE SHOULD BE NO ELECTRICAL CONNECTION TO THE MACHINE. THE ELECTRICAL PANEL MUST BE CLOSED AND SECURED. WHEN THE MAIN SWITCH IS ON, THERE IS HIGH VOLTAGE THROUGHOUT THE ELECTRICAL PANEL (INCLUDING THE CIRCUIT BOARDS AND LOGIC CIRCUITS) AND SOME COMPONENTS OPERATE AT HIGH TEMPERATURES. THEREFORE, EXERCISE EXTREME CAUTION WHEN WORKING IN THE PANEL.

1. Set the main switch at the upper right of the electrical panel on the back of the machine to OFF. 2. Using a screwdriver, unlock the two latches on the panel door, unlock the cabinet with the key, and open the door.

Reference Manual June 2007 (Vertical)

Installation

11

3. Take sufficient time to check all the components and connectors associated with the circuit boards. With the power off, push on them gently to make sure that they are seated in their sockets. Look for any cables that have become disconnected, look for any signs of damage and loose parts in the bottom of the panel box. If there are any signs that the machine was mishandled, call the factory before proceeding.

I NSTALLATION OF P ENDANT (VS SERIES ONLY )


CAUTION! Use proper lifting equipment and techniques when performing the following steps.

1. Unpack and remove the pendant from its shipping crate. Remove the small retaining plate bolted to the bottom of the pivot of the pendant. 2. Position the pendant so that the pivot point is near the pendant pivot block already bolted to the table casting. Ensure the pendant wiring is moved out of the way and will not interfere in fitting the pendant pivot to the pendant pivot block. 3. Insert the pendant pivot into the pendant pivot block. Secure the pendant using the plate and hardware removed in Step 1.
NOTE: When inserting the pendant pivot into the pendant pivot block, make sure the pendant arm is perpendicular to the table, as shown in the figure.

Pivot Block Top Cover

Trough Extension w/Covers Table Cable Trough

Pendant Pivot Block Table Cable Trough

4. Place the table cable trough on the floor. Arrange the pendant wiring through the pendant pivot block and into the trough. Slide the trough under the mill table. 5. Move to the opposite side of the table (chip auger side). Remove the 1/4-20 BHCS from the trough cover and remove the cover. Cut the cable ties and unroll the control cabinet wiring into the trough. 6. Attach the trough extension to the flange of the table bed. Route the cables from the table cable trough up into the trough extension. Connect the cable ends from the pendant to the cable ends from the control cabinet. 7. When the proper cable connections have been made, attach all the trough covers to the trough assembly using 1/4-20 BHCS. 8. Attach the table cable trough to the table and secure with 1/4-20 BHCS. 9. Move to the pendant side of the table. Attach the table cable trough to the bottom of the pendant pivot block using 1/4-20 BHCS. 10. Attach the pivot block top cover to the pendant pivot block. Secure with 1/4-20 BHCS.

Reference Manual June 2007 (Vertical)

Installation

12

AIR CONNECTION
CAUTION! Working with the air service required for a mill can be hazardous. Make sure that pressure has been removed from the air line before connecting/ disconnect it from the machine, or servicing parts of the air system.

Air Filter/Regulator Oil Filter

Oil Pump Pressure Gauge

Hose Barb (Shop Air) Front Air Nozzle Air Line Oil Fill (To High Mark) Oil Reservoir

1. When the machine leaves the factory, the air filter is empty, and the lubricator reservoir tank is full. However, they should be checked and serviced if required before compressed air is supplied to the machine. 2. With the pressure off in the air line, connect the air supply to the hose barb next to the air filter/ regulator. If the fitting supplied is not compatible, replace it. 3. Start the compressor; set it between 100 and 150 psi. Set the regulator on the machine to 85 to 90 psi. 4. Prime the lubricator to make sure it is working. To prime the lubrication system, pull up on the handle on top of the reservoir tank.
CAUTION! NEVER push down on the primer handle. It gradually returns to the down position by itself, and the corresponding pressure increase can be seen on the pressure gauge.

NOTE:

Depending on the position of the cam that drives it, the lubrication system may not activate until a few minutes after the machine is started. However, if there is a problem with the system, an alarm will stop the machine.

5. Verify spindle air pressure using the gauge located behind the Air Regulator panel. Most machines should show 17 psi. Adjust if necessary. VF machines equipped with a 15K spindle must have the regulator set to 20 psi.

E LECTRICAL C ONNECTIONS
NOTE: The machine must have air pressure at the air gauge, or a Low Air Pressure alarm will be present on power-up. Working with the electrical services required for the mill are extremely hazardous. The electrical power must be off and steps must be taken to ensure that it will not be turned on while you are working with it. In most cases this means turning off a circuit breaker in a panel and then locking the panel door. However, if this is not the case or are not sure how to do this, check with the appropriate personnel or obtain the necessary help before continuing.

CAUTION!

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Installation

13

WARNING!
KEEP THE ELECTRICAL PANEL CLOSED AND THE LATCHES ON THE DOOR SECURED AT ALL TIMES EXCEPT DURING INSTALLATION AND SERVICE. AT THOSE TIMES, ONLY QUALIFIED ELECTRICIANS MAY ACCESS TO THE PANEL. WHEN THE MAIN CIRCUIT BREAKER IS ON, THERE IS HIGH VOLTAGE THROUGHOUT THE ELECTRICAL PANEL (INCLUDING THE CIRCUIT BOARDS AND LOGIC CIRCUITS) AND SOME COMPONENTS OPERATE AT HIGH TEMPERATURES. THEREFORE, EXTREME CAUTION IS REQUIRED.

Ground Line
L1 L2 L3

Main Circuit Breaker

1. Hook up the three power lines to the terminals on top of the main circuit breaker at the upper right of the electrical panel. Connect the separate ground line to the ground bus to the left of the terminals.
NOTE: Make sure that the service wires actually go into the terminal-block clamps. (It is easy to miss the clamp and tighten the screw. A poor connection will cause the machine to run intermittently or have other problems, such as servo overloads.) To check, simply pull on the wires after the screws are tightened.

2. After the line voltage is connected to the machine, make sure that the main circuit breaker (at top right of rear cabinet) is OFF. Turn ON the power at the source. Use a digital voltmeter and appropriate safety procedures, to measure the voltage between all three pair phases at the main circuit breaker and write down the readings. The voltage must be between 195 and 260 volts (360 and 480 volts for high-voltage option).
NOTE: Wide voltage fluctuations are common in many industrial areas; you need to know the minimum and maximum voltage which will be supplied to the machine while it is in operation. The U.S. National Electrical Code specifies that machines should operate with a variation of +5% to -5% around an average supply voltage. If problems with the line voltage occur, or low line voltage is suspected, an external transformer may be required. If you suspect voltage problems, the voltage should be checked every hour or two during a typical day to make sure that it does not fluctuate more than +5% or -5% from an average. Make sure that the main circuit breaker is set to OFF and the power is off at your supply panel BEFORE you change the transformer connections. Make sure that all three black wires are moved to the correct terminal block and that they are tight.

CAUTION!

3. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three black wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in Step 2 above. There are four positions for the input power for the 260-volt transformer and five positions for the 480-volt transformer. The labels showing the input voltage range for each terminal position are as shown in the following illustrations.

Reference Manual June 2007 (Vertical)

Installation

14

4. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this transformer for use on 240 and 400V machines (32-0964B and 32-0965B, respectively). The 240V transformer has two input connectors located about two inches from the transformer, which allow it to be connected to either 240V or 200V. Users that have 220V-240V RMS input power should use the connector labeled 240V, while users with 190-220V input power should used the connector labeled 200V. Users with the External High Voltage Option should use the 240V connector if they have 420V-510V 60Hz power or the 200V connector if they have 50Hz power. Failure to use the correct input connector will result in either overheating of the main contactor or failure to reliably engage the main contactor. The 480V transformer has three input connectors, labeled 360V, 400V and 480V. Users with 340-380V 50Hz power should use the 360V connector while users with 380-440V 50Hz power should use the 400V connector. The 480V connector is not currently used.

441-480V 221-240V

T5 24 VAC WARNING:
381-440V 190-220V MEASURE VOLTAGE AT MAIN
CIRCUIT BREAKER AND CONNECT SUPPLIED SHORTING PLUG TO CORRESPONDING CONNECTOR ON THIS TRANSFORMER 340-380V

5. Set the main circuit breaker to ON. Check for evidence of problems, such as the smell of overheating components or smoke. If such problems are indicated, immediately set the main circuit breaker to OFF and call the factory before proceeding.
Ouput Power Input Power
24 TB2 0V OU T

T5 Transformer Main Circuit Breaker

48

8-4

58

DA

NG ER

INC OM

45 7-4 26 29V 0-2 44 V


ING LIN EV

2-3 V LT AG HIG 22 77V E TA 6-2 PS HV 11 376 (74, V -3 75 21 54V OL , 76 0-1 ) 12 TB1 TA 95 0V V GE OU T DA NG ER !!!

!!!

42 8-4 24 03V 3-2 40 27

WARNING!
THE THROUGH THE SPINDLE COOLANT (TSC) PUMP IS A THREE-PHASE PUMP AND MUST BE PHASED CORRECTLY! IMPROPER PHASING WILL CAUSE DAMAGE TO THE TSC PUMP AND VOID THE WARRANTY. REFER TO THE TSC START-UP SECTION IF YOUR MACHINE IS EQUIPPED WITH TSC.

6. After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It should be the same as the measurements where the input power connects to the main circuit breaker. If there are any problems, check the wiring.

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7. Apply power to the control by pressing the Power-On switch on the front panel. Check the high voltage buss on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom of the drive). It must be between 310 and 360 volts. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory. Next, check the DC voltage displayed in the second page of the Diagnostic data on the display. It is labeled DC BUS. Verify that the displayed voltage matches the voltage measured at pins 2 and 3 of the Vector Drive 7 VDC. 8. Electrical power must be phased properly to avoid damage to your equipment. The Power Supply Assembly PC board incorporates a Phase Detect circuit with neon indicators, shown below. When the orange neon is lit (NE5), the phasing is incorrect. If the green neon is lit (NE6), the phasing is correct. If both neon indicators are lit, then you have a loose wire; check the connections. Adjust phasing by swapping L1 and L2 of the incoming power lines at the main circuit breaker.
PHASE DETECT
(FOR 3 PHASE ONLY)

PASS
NE6

FAIL
NE5

WARNING!
All power must be turned off at the source prior to adjusting phasing.

9. Turn off the power, close the door, lock the latches, and turn the power back on. 10. Remove the key from the control cabinet and give it to the shop manager.

I NSTALLATION PROCEDURE FOR EXTERNAL 480V TRANSFORMER

Introduction
The external transformer adds to overall machine reliability and performance; however it does require extra wiring and a place to locate it. The external transformer provides electrostatically shielded isolation. This type of transformer acts to isolate all common mode line transients and improve EMI conducted emissions. The external transformer has a 45 KVA rating. It is a 480V 60Hz only transformer.

Installation
The transformer should be located as close to the machine as possible. The input and output wiring of the transformer should conform to the local electrical codes and should be performed by a licensed electrician. The following is for guidance only, and should not be construed to alter the requirements of local regulations. The input wire should not be smaller than 6 AWG for the 45KVA transformer. Cable that runs longer than 100" will require at least one size larger wire. The output wire size should be 4 AWG. The transformer is 480V to 240V isolation transformers with delta-wound primary and secondary windings. The primary windings offer 7 tap positions, 2 above and 4 below the nominal input voltage of 480V. The primary side should be wired as follows:

Input Voltage Range


493-510 481-492 469-480 457-468 445-456 433-444 420-432

Tap
1 (504) 2 (492) 3 (480) 4 (468) 5 (456) 6 (444) 7 (432)

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This should produce a voltage on the secondary side of 234-243 V RMS L-L. Verify this and readjust the taps as required. At the machine, connect the cables at the input of the internal 230V transformer to the 227-243V taps. Apply power to the machine and verify that the DC voltage between pins 2 and 3 of the Vector Drive (2nd and 3rd pins from the left) is 329-345VDC. If not, return to the 480V isolation transformer and readjust the taps as required. Do not use the taps on the internal 230V transformer to adjust the voltage.

50Hz Installations
The external transformers are 60Hz rated, and cannot be used at 50Hz without derating the input voltage. For these applications, the internal 230V transformer should be tapped on the lowest setting (195-210V RMS). The external transformer should be tapped according to the following table. If these tap settings do not produce a DC bus voltage between pins 2 and 3 on the Vector Drive between 320 and 345VDC, readjust the taps on the external transformer as required. Do not move the taps on the internal transformer from the lowest position. Input Voltage Range 423-440 412-422 401-411 391-400 381-390 371-380 355-370 Tap 1 (504) 2 (492) 3 (480) 4 (468) 5 (456) 6 (444) 7 (432)

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M ACHINE P OWER ON

Remove Shipping Brackets


CAUTION! DO NOT press POWER UP/RESTART on the control panel while the shipping brackets are under the spindle. Also, do not press the X, Y, or Z buttons or the jog handle while the shipping brackets are located under the spindle.

Spindle Head Shipping Bracket


Loosen the four SHCS (three screws are in the table, and one is in the spindle head) holding each shipping bracket under the spindle head, and remove the two brackets.
Column Shipping Brackets

SHCS (8)

Shipping Brackets (2) T-nuts (6)

Rear Shipping Bracket

Machine Shown with Rear Cover Removed


VF 1-11 Shipping Bracket Mill Drill Shipping Bracket Additional Shipping Brackets (MDC only)

VF-11 and VR-11 Door Shipping Brackets


The operator doors are secured, top and bottom, with blocks. Remove the bolt that secures each block.

Mill Drill Rear Shipping Bracket Removal


1. Remove the screws that secure the rear panel. 2. Remove the four screws that hold the shipping bracket to the spindle and saddle castings. 3. Remove the rear shipping bracket and the two column shipping brackets (There are three bolts in each one). 4. Replace the rear panel.

MDC Pendant Arm Shipping Bracket Removal


1. Remove the pendant shipping bracket, there are three screws holding it in place. 2. Replace the pendant stop; orient it as shown in the illustration. Use the screws removed from the shipping bracket.
Existing Screw Pendant Stop (Rotated 1808)

Pendant Stop Existing Screws

Shipping Bracket

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P OWER O N
1. With the main switch on the electrical panel set to ON, press and release POWER ON at the upper left of the control panel. You will hear a click in the back of the machine and the fans will energize. After a few seconds, the display will appear on the screen. 2. Press and release SETNG / GRAPH. Page down to the last page (press and release PAGE DOWN several times). Cursor to Setting 53, JOG W/O ZERO RETURN (with the cursor down key). Press and release the cursor right key and then press and release the WRITE key to turn this setting on. Turning on JOG W/O ZERO RETURN bypasses the zero return interlock. 3. Press and release the RESET button twice, or until there are no alarms, to turn the servos on. (The message ALARM appears at the lower right of the screen if any alarms are in effect.)
NOTE: If any alarms are present and cannot be cleared with the RESET button, press and release the ALARM / MESGS button for more information on the alarms. If you are unable to clear the alarms, write down the alarm numbers and call the factory.

4. Press and release the HANDLE JOG button and check the screen for the JOGGING Z AXIS HANDLE .001 message. If the message does not read .001, press and release the .001 button next to the HANDLE JOG button. If the "JOGGING__" message shows the X- or Y-axis instead of Z, press and release the +Z button. Verify that the head will travel SLOWLY (not more than 0.001 inch per impulse the ".001" part of the Z-axis message). Jog the Z-axis to the top of its travel. For the VF-1/2/3/4, jog the Z-axis to the top of its travel, and remove the flex tube cradle as shown.

NOTE:

The upper numbers on the buttons next to HANDLE JOG are for the jog handle use, and the lower numbers are for the jog speed in inches per minute when using the JOG buttons on the keypad.

5. Once you are certain that the Z-axis is working correctly (that it operates smoothly and there are no strange noises, etc.), make sure that all alarms are clear check for the ALARM message at the lower right of the screen. Next, close the doors and press and release the ZERO RETURN button followed by the AUTO ALL AXES button. The Z-axis moves up slowly. After it has reached its home position, the X- and Y-axes move to their home positions. IMPORTANT!! To verify correct hydraulic counterbalance pressure, jog the head to the top and bottom of its travel, and ensure the tank pressures match those printed below and on the tanks.
VF-3/4 Machi ne at Top of Travel 1150 psi VF-6-11 7 5 0 p si VF-6/7/10 w/50T Spi ndle 1150 psi VF-8/9/11 w/50T Spi ndle 1 5 5 0 p si VF-5 w/40T Spi ndle 8 7 5 p si VF-5 w/50T Spi ndle 1100 psi VR 1 8 0 0 p si VS 1 2 5 0 p si

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VF/VM//VR S ERIES L EVELING O VERVIEW


Leveling of the machine is required to obtain the correct right angle geometry of the VMCs X, Y, and Z axes. Incorrect level will result in out-of-round circle milling and incorrect linear interpolation. Leveling is done in two steps: rough leveling to ensure the machine is level for coolant and oil drainage, and fine leveling for axis geometry. Finally, the spindle sweep is checked. Leveling is done without removing any covers.
NOTE: Many factors can affect a machines ability to remain level the rigidity of the floor, the stability of the support under the floor, trains or trucks passing nearby, seismic activity, and so on. Therefore, until your experience shows how often re-leveling is required, you should check the machines level frequently after it is installed.

Wiring connections to power the machine must be made before the Levelling Procedure can be followed.

X-AX IS

Use a precision bubble level with each division equal to 0.0005 inch per 10 inches, or .05 mm per meter, or 10 seconds per division. Before starting, check the accuracy of your level. Set it on the table on the X axis and record the reading. Then turn it 180o and the reading should be the same. If it is not, the level is out of calibration and should be adjusted before you continue.

Rough Leveling
NOTE: For the VF-1/2, it may be necessary to pull the coolant tank toward the back of the machine to access the leveling screws.

1. Screw the four leveling screws at the corners through the base until the base is 2" to 3" above the floor. That translates into a minimum of one inch of the leveling screw extending out of the bottom of the base of the machine, or one inch between the pads and the casting. Turn each screw until the tension is about the same as the tension on the other screws (it takes the same effort to turn each screw). Screw the jam nuts onto the leveling screws, but do not tighten them down.

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2. Install the two center leveling screws, ensuring that they do not touch the floor. Screw the jam nuts onto the leveling screws, but do not tighten them down. 3. Use HANDLE JOG set for 0.01 on the X and Y axes for the leveling procedure. This provides a good rate of travel as you manually move the table. 4. Using the jog handle, center the table under the spindle. You do not need to move the table while roughleveling the machine. 5. Place the level parallel to the Y axis (side to side) on the table and observe the bubble. If the bubble is centered, the table is level on this axis. If the bubble is off to the left of the level, it means that the left side of the table is high. And, conversely, if the bubble is off to the right, it means that the right side of the table is high. Adjust the two front leveling screws until the level reads +/- 0.0005. 6. Rotate the level head so that it is parallel to the X-axis. Adjust the right front and rear leveling screws until the level reads +/-0.0005.
NOTE: Make sure that the bubble has steadied before you take the reading.

7. Turn the screws on the low side of the machine clockwise (screw them in) a little at a time and check the level until the bubble is centered.
NOTE: In most cases it is better to raise a side or corner than it is to lower it when you lower a machine there is a greater risk of running out of adjustment.

8. Repeat the previous steps with the level on the Y axis (front to back). 9. Continue this process until the machine is level on both axes.
NOTE: If the level is off on both axes, it indicates that one corner of the machine is high or low.

10. As the process continues, the leveling screws are turned in smaller increments 1/4 turn, 1/8 turn, and smaller. Also, as the machine is leveled, make sure that the tension continues to be equal on the screws at all four corners.
NOTE: The following procedure for fine-leveling the machine must be performed exactly as noted to ensure the machine will meet all quality standards for machining operations. Failure to follow these guidelines will prevent the machine from being truly leveled and result in poor machining finishes.

Fine Leveling
11. With the table centered, place the bubble level in the center of the table parallel to the Y-axis. Using the jog handle, move the Y axis, stopping at the front, middle, and back of the travels. The objective is to adjust the level to make the Y-axis guides parallel. The bubble level must indicate the same reading at each position (front, middle, back). Adjust the front leveling screws as necessary. To check for Y-axis roll, position the level perpendicular to the Y-axis and jog to each end of travel. If necessary, adjust the front right or left leveling screw. To check the X-axis, jog axis to each end of travel and tighten the middle leveling screws against the leveling pads. Verify X-axis roll by placing level parallel with the Y-axis, jog X-axis to each end of travel. Repeat the above steps until there is no perceptible X or Y-axis roll. The following procedure is simply a check of machine level. If it does not meet specifications, then you must repeat this operation. Do not adjust the middle screws at this point. Refer to the Machine Inspection Report that accompanies your machine. Check your results with those of the report under the Table Travel Flatness verification. By duplicating these results, you will obtain the same alignment specifications that were achieved at the factory.

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12. Place a 0.0005 test indicator in the spindle and sweep a 10" diameter circle on the table (see the Machine Inspection Report in the manual for the results of this test at the factory). Grease the dimple in each of the two remaining pads, locate them under the middle leveling screws, and use these screws to compensate for any error. If there is no error, tighten the screws evenly until they contact the pads. When fine leveling is completed, tighten the jam nuts on the leveling screws.

T OOL CHANGER ASSEMBLY (VR SERIES )


CAUTION! Use extreme caution when installing the tool changer. Since the machine has not been leveled yet, the tool changer may swing and cause serious injury or machine damage.

1. Remove the tool changer components from their shipping crate. 2. IMPORTANT! Remove the shipping bracket from the tool changer to the column (2 SHCS). Remove the tool changer enclosure from inside the machine (18 BHCS). 3. Remove the 1/2"-13 x 1 1/4" SHCS that mounts the tool changer link to the column.
Tool Changer Rear Mount Air Cylinder Tool Changer Link

Shaft Link Stabilizer Column

3 33 32 31 30 29 28 27 26 25 24 23

Tool changer assembly.

4. Hoist the tool changer rear mount into place and mount it with six 1/2"-13 x 1 1/4" SHCS, two 1/2"-13 x 3" SHCS, and two spacers. 5. Carefully swing the tool changer into place. Attach the air cylinder rod with the 5/8"-11 x 7" SHCS. Attach the stabilizer rod with the 1/2 x 5" SHCS. 6. Mount the tool changer link to the rear mount with two 1/2"-13 x 1 1/4" and the shaft link. 7. Connect the air lines (2) at each end of the air cylinder. IMPORTANT! The air line from the bottom fitting of the lube/air panel connects to the rear fitting on the air cylinder. The air line from the top fitting of the lube/air panel connects to the front fitting on the air cylinder. 8. Hoist the tool changer enclosure into place, so that it protrudes from the rear of the machine (see figure at right). Attach it with the 18 BHCS. Attach the bracket from the column to the tool changer enclosure with 6 BHCS.

T OOL C HANGER A LIGNMENT (VR S ERIES)


This procedure will align the tool changer to the spindle in the Y axis. 1. Zero Return All Axes. Place cardboard on the table for protection. 2. Place a tool in the spindle. Press the ORIENT SPINDLE key. Ensure there is no tool in the tool changer pocket facing the spindle. Press Emergency Stop. 3. Swing the tool changer into the tool change position by hand. Mark the top of the tool changer link with paint to establish an initial position.

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NOTE:

Ensure the spindle does not spin. When E-Stop is pressed, the spindle is free to rotate, and may lose its orientation.

4. Check the tool changer pocket position in relation to the tool in the spindle. If the tool changer is misaligned in the Y-axis, continue with this procedure. If the tool changer is misaligned in the X-axis, contact the Service Department at Haas Automation.

Link

Locknut (2)

5. Loosen the locknut at each end of the tool changer link. Note that one is a left-hand thread and one is a right-hand thread. Once the locknuts are loose, rotate the link clockwise, and then counterclockwise until resistance is felt in each direction. Rotate the link to the center of the area in which the link turns freely. 6. Tighten the locknuts at each end, while holding the link in place with a wrench. 7. Push the tool changer away from the spindle. Zero Return All Axes, and the tool changer should move back to the HOME (out of the work envelope) position. 8. Run a number of tool changes, and ensure they are performed smoothly. If not, perform this procedure again.

O UTRIGGER L EVELING PROCEDURES


NOTE: Not all mills are equipped with outriggers. The standard mill leveling procedures must be completed before starting this section.

VMC Outriggers 60"

50" Base Casting Front


Outrigger Locations Outrigger Leveling Screw Locations

1. Locate the leveling pads underneath the outrigger leveling screws. Grease the dimples and keep the screws at least 1/4" above the pads. 2. Place a level in the center of the table and parallel to the X-axis. 3. Jog the Y-axis back (toward the column) to max travel.

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4. Starting from either the left or right of the machine, jog the table to the max X travel and over the rear outrigger leveling screw. DO NOT MOVE THE LEVEL. 5. Tighten the leveling screw onto the rear pad, which will raise the table and zero the level. Over-tightening the outrigger leveling screws will result in poor machine performance. 6. Jog the Y-axis forward to max travel and repeat step 5. 7. Jog the X-axis to max travel over the other outrigger, and repeat the leveling process. 8. Check level through full X and Y axes ranges of travel.

SHEETMETAL SUPPORT PADS


1. Screw the support pads down to the floor. 2. Turn them an additional 1/4 turn once they have come in contact with the floor. Additional tightening of the pads against the floor may affect the level of the machine. 3. Lock in place with the jam nut.

CAUTION!

To avoid damaging the sheetmetal when moving or shipping the machine, fully retract the support pads.

LEVELING T HE MDC-500
Leveling of the machine is required to obtain the correct right angle geometry of the machine's X, Y, and Z axes. Incorrect level will result in out-of-round circle milling and incorrect linear interpolation. Leveling is done in two steps: rough leveling to ensure the machine is level for coolant and oil drainage, and fine leveling for axes' geometry. Finally, the spindle sweep is checked.
NOTE: Many factors can affect a machines ability to remain level the rigidity of the floor, the stability of the support under the floor, trains or trucks passing nearby, seismic activity, and so on. Therefore, until experience shows how often releveling is required, check the machines level frequently after it is installed.

Use a precision bubble level with each division equal to 0.0005 inch per 10 inches, or .05 mm per meter, or 10 seconds per division. Before starting, check the accuracy of your level. Set it on the table on the X-axis and record the reading. Then turn it 180 and the reading should be the same. If it is not, the level is out of calibration and should be adjusted before you continue. Screw the four leveling screws at the corners through the base until the base is 3" to 3 1/2" above the floor. Verify that the coolant tank slides under the machine base with 1/4 to 1/2 of clearance. That translates into a minimum of 1 3/4" of the leveling screw extending out of the bottom of the base of the machine, or one inch between the pads and the casting. Turn each screw until the tension is about the same as the tension on the other screws. Screw the jam nuts onto the four (4) leveling screws, but do not tighten them down.

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Rough Level
1. Clean the pallet in the machine and precision level of all debris. Center the X and Y axes. 2. Loosen right front leveling screw so there is at least 1/4" between the tip of the leveling screw and the leveling pad. The two middle screws should not be touching the floor or the leveling pads. 3. Position the precision level on the center of the pallet parallel to X-Axis. Adjust left-rear leveling screw until the level reads +/-.0005". 4. Position level head on center of the pallet, parallel to Y-Axis. Adjust left-front leveling screw to read +/.0005".

Roll
1. Jog the pallet towards the spindle. Position the precision level on center of the table parallel to X-Axis. 2. Adjust left-rear leveling screw until a reading of +/-.0002" is achieved. Note the levels reading. 3. Jog the pallet towards the pallet changer. Adjust the right front leveling screw so that readings at both front and back of machine are within +/-.0005" of each other.

Pitch
1. Tighten the middle leveling screws until they are just touching the leveling pads (very light pressure). 2. Position the level on the pallet parallel to the Y-axis. Jog the Y-axis from one end to the other. Adjust the middle screws only until a maximum pitch deviation is .0005"/10" over full travel. 3. Turn the level 90 degrees and verify that your pitch changes have not introduced too much roll deviation in the Y-axis. Adjust the 2 middle screws only to fix any excess roll deviation. Adjust the two screws together by equal amounts (one up one down) to fix the roll without affecting the pitch.

Verify Column Level


1. Place the precision level on the machined surface on top of column parallel to Y-axis. 2. Jog the X-axis from one side to the other, note the reading from one end of travel to the other. The maximum allowable deviation is 0.0003". 3. Rotate the precision level so it is parallel to X-axis. Jog the X-axis from one side to the other, note the reading from one end of travel to the other. The maximum allowable deviation is 0.0003".

Electronic Level

X-Axis
MDC-500

IMPORTANT!!! Refer to the Machine Inspection Report that accompanies your machine. Check your results with those of the report under the Pallet Flatness verification. By duplicating these results , you will obtain the same alignment specifications that were achieved at the factory.

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VS S ERIES L EVELING O VERVIEW


Leveling of the machine is required to obtain the correct right angle geometry of the mills X, Y, and Z axes. Incorrect level will result in out-of-round circle milling and incorrect linear interpolation. Leveling is done in two steps: rough leveling to ensure the machine is level for coolant and oil drainage, and fine leveling for axis geometry. Finally, the spindle sweep is checked. Many factors can affect a machines ability to remain level the rigidity of the floor, the stability of the support under the floor, trains or trucks passing nearby, seismic activity, and so on. Therefore, until your experience shows how often re-leveling is required, you should check the machines level frequently after it is installed. Wiring connections to power the machine must be made before the Levelling Procedure can be followed. It is our recommendation that the machine be anchored in place for best and most consistent results while in use. The anchoring bolts (in accordance with the anchoring instructions Haas document ES0095) should be installed prior to the machine being set in place. The X-axis auger trough must be removed before mating the column base to the table base. The auger trough will remain off the table base until the leveling and squaring procedures are completed. It is recommended that the table base be removed from the truck and set in place before the column base to better accommodate removal of the auger trough and keep the installation process moving smoothly. The installation process is further aided if, when each base is set in place, a very rough leveling procedure is done. The ideal distance from the floor to the bottom of the two bases is 2.5 (64mm). The use of a machinist scale or small gauge blocks will expedite the process. While all leveling screws and leveling pads are in place measure from the floor to the bottom of each base until the distance is very close to the 2.5 (64mm) height. This will accomplish two things: First, that the machine is set to the proper height to receive the coolant tank and, second, that the machine will be much closer to level than without having done this procedure. The installation procedure will necessarily follow the general outline below (a more detailed explanation follows). Depending on the available space and equipment it may be simpler to place the column base assembly before the table base assembly. This outline considers that it is easier to place the table base assembly first. Regardless of which assembly is placed first, the concepts of the general outline need to be adhered to: Remove the table base assembly from the truck and set in place Remove the X-axis auger trough and rough level the table base Stone and clean the table base mating flange Remove the column base assembly from the truck Stone and clean the column base mating flange Move the column base to mate with the table base Be certain that all connecting bolts are in place but not tightened Attach the Pendant and Pendant Arm Support Assembly to the front of the table base Run the Pendant electrical wires under the table and connect them in the wire covers on the back of the table Rough level the column base assembly Remove the dust covers from the column assembly Install the counterbalance cylinder and charge the system Remove shipping blocks from the table base assembly Connect all air/electrical/oil lines between the two assemblies Remove shipping blocks from the column base assembly Power up the control Fine level the table base assembly Fine level/square the column base assembly Fully tighten the connecting bolts and adjust fine level/square Fully check machine geometry Replace the X-axis auger trough Install the coolant supply system Check all motors for rotation/phasing

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M ACHINE L EVELING AND GEOMETRY C HECK (VS)


At this point the machine is completely unblocked and all axes are enabled.
Cable Access Hole Table Base Mating Flange

Column Base Mating Flange

SHCS (19)

Lockwasher (19)

The following criteria should have already been met at this point The machine correctly placed with respect to the anchoring points. The very rough leveling has taken place, ensuring that the bottom of the two bases are very close to 2 inches off the floor. The mating flanges of the two bases have been pulled into contact. The screws that connect the two bases have been backed off and can rotate freely.

O VERVIEW OF L EVELING THE M ACHINE


When leveling the machine the best results are achieved when the entire machine is leveled with respect to the earth. For the table that means that over the entire travel of the X-axis the table is level to earth in the direction across the table as well as along the length of the table. For the column base the same concept applies, but a slight modification may occur when checking the perpendicularity of the Z-axis to the X-Y plane of the machine. Leveling and squaring the machine is an iterative process where a change of level in one part of the machine can and will affect the geometry in another part of the machine. The process is begun by establishing a known level datum plane that is the table surface in the center of travel, and all subsequent geometry is with respect to that plane. The general profile of the process of leveling and squaring the machine is as follows: The table base will be leveled to earth The column base will be leveled to earth The X-Y axes will be checked for perpendicularity The table will be swept for parallel to the X-Y plane of the machine The Z axis will be adjusted for perpendicularity to the Y axis The Z axis will be adjusted for perpendicularity to the X axis The mating flange will be completely tightened Final leveling, squaring, and anchoring Geometry check

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Establishing the Table as the Datum Surface


1. Remove all but five of the mating flange connecting screws. The five that should be left in position are the four that are in the corners of the mating flange and the one that is in the center of the top of the mating flange. Be sure that the five remaining screws are able to rotate freely, indicating that no binding will occur by changing the level of the table base. (The freedom of these screws is important to the process, and they should be checked frequently since, if they bind, the leveling process associated with the column base could alter the table base level). If the screws do begin to bind, the column base should be raised or lowered accordingly to free the screws. While maintaining full face contact of the mating flange surface.

2. Zero return all axes 3. Move the X-axis so the position is 75 inches, which is the midpoint of X-axis travel. 4. Place two levels at right angles to each other as close as possible to the center of the table. One will show the level across the width of the table and the other will show the level along the length of the table. 5. Focus on leveling the table only in this X-axis position to establish a primary datum for the machine. Adjust only the four leveling screws indicated (the two on the table base closest to the column base, and the two immediately on the other side of the table base). No other leveling screws on the table base should be in contact with the leveling pads at this time.

Column casting Step #6 Step #5 Table casting Step #6

6. When the table level is close to zero in both directions, the four very end leveling screws may be brought down to touch the leveling pads. 7. Continue to level the table base until both levels on the table read zero.

Leveling the Column Base


1. Check that the mating flange screws are still free to turn so the following steps do not affect the level of the table base primary datum. 2. Allow only the four leveling screws on the corners on the column base are to be in contact with the leveling pads at this time. 3. With the column at approximately center of travel, lay one granite parallel across the linear guides as close to the table as possible and another granite parallel across the linear guides as near the rear of the machine as possible. 4. Place a level on each parallel and adjust the level of the column from side to side.

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5. Check the freedom of the mating flange screws to be certain there is no binding. Raise or lower the column base as necessary to free screws. 6. On the guide nearest the control, place one level on the linear guide in front of the column and one level on the linear guide to the rear of the column. Adjust the level of the machine in the direction of Y-axis travel. Move the levels to the opposite linear guide and complete the process. Repeat steps 3-6 until the column base is level. Be certain throughout the process that the mating flange screws are free to rotate. A binding of the screws will mean that the column base will have to be raised or lowered as necessary and the leveling process of the column base will need to be repeated. 7. When the column base is level to earth in both directions, the six center leveling screws should be lowered to touch the leveling pads. 8. Remove the granite parallels from the column base.

Checking the Level of the Column Base


1. Handle jog the column to the rear. 2. Place a single level on the top of the spindle head parallel with the X-axis of the machine. It is very unlikely that this surface will read zero, do not expect it to. Note the reading that is present. 3. While monitoring the level, move the column all the way forward and check if there is a change in the level reading. If there is no change of reading, then the column base has no twist. If there is a twist in the base, this must be corrected. 4. Place an indicator in the special tool and touch off on the table surface. Sweep the table in the Y-axis direction only, to determine, and correct column base flatness in the Y-axis direction. This is a very sensitive measurement method and corrections to this level should be made in conservative steps.
NOTE: Corrections that are made in this check of the column base level require a repeat of the basic leveling procedure and a recheck of the level be done.

Sweeping the Z-Axis


Before continuing to the final attachment of the column base to the table base the Z-axis needs to be swept. Until now we have assumed that the geometry of the column is perfectly perpendicular to the plane of the column base, but that may not be close enough to maintain the required machine geometry.

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xi

29

Z-Axis Motion Will Be Swept Parallel To Line Of Intersection Y-Z Plane X-Y Plane

X-Z Plane

Sweeping the Z-axis is accomplished using a cylinder square, which will verify that the line of Z-axis motion is perpendicular to the X-Y plane described by the Y-axis motion and the X-axis motion. The X-Y plane, as defined by the leveling process, should be equivalent in the squaring function as the parallel plane described by the surface of the table. The Z-axis line of motion will be checked by comparing it to the line of intersection of the X-Z plane and the Y-Z plane. By assuring that each of these planes are perpendicular to the X-Y plane within specification, the machine geometry will be preserved.

Final Connection of the Column Base to the Table Base


1. Completely remove the front Y-axis way cover from the machine. 2. Remove the front Y-axis way cover bottom cover and the way cover support bars to allow access for properly tightening of the connecting screws. 3. Before inserting and tightening all the connecting screws, recheck the table level to be certain that the leveling process of the column base did not affect table level. 4. Tighten the connecting screws with lock washers in place and loctite on the screws.

Geometry Check After Mating the Two Bases


Before continuing two fundamental geometry checks need to be made. The first is the perpendicularity of the Xaxis to the Y-axis, and the second is to verify the sweep of the Z-axis. 1. The sweep of the X-axis to the Y-axis is accomplished using a granite square. Set zero by sweeping the Yaxis on one side of the square, and then to verify that the motion of the X-axis is perpendicular by sweeping the adjacent side of the square. If the X and Y axes are out of tolerance, there almost certainly is contamination or damage between the mating flange surfaces that is creating this error. The assembly will have to be disassembled, the surfaces re-stoned and cleaned, and the entire leveling/squaring process repeated to this point. 2. Verify the sweep of the Z-axis by repeating the previous section (Sweeping the Z-Axis).

Fine Leveling the Machine


Now that the preliminary leveling is done and the bases are securely mated, the machine can be treated as a unit with confidence that the geometry will be maintained as long as adequate control is maintained in the fine leveling process. The process begins with loading the remainder of the leveling screws very lightly and working into an equally loaded situation that does not affect the geometry already achieved. The column base will be the first section affected, and will be fine leveled with respect to the table at the middle of travel.
CAUTION! Do not rush the leveling process. Any drastic attempt to fine level the column base will be propagated to the table base assembly and may not be correctable if not addressed early in the process.

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The table base is more complicated to fine level, and small steps will be taken to preserve the level to earth established at the middle of travel. The first step of the process will be to begin to load the leveling screws over the length of the base. The second step will be to begin to pull the overall length into earth level. The third step will be to fully pull the base into level. 1. Begin with the column base assembly. Place the level on the spindle head parallel with the Y-axis and run the column through the range of travel. If no deviation in the reading exists, the column base is flat in the direction of the Y-axis. Move the level to each of the linear guide surfaces in front of the column. If the readings are zero, the column is flat to earth in the direction of the Y-axis. Power up the control-axis. Place the level on the spindle head parallel to the X-axis. Run the column through the range of travel. If no deviation in the reading exists, the column base exhibits no twist. Place the granite parallels across the linear guide surfaces in front and behind the column. Place the levels on the granite. If the readings are zero, the column base is flat to earth in the X-direction. 2. Move the levels to the table and place them as close to the center as possible. One level should be parallel to the X-axis and one level should be perpendicular to the X-axis. If the readings are still zero, then the table at the center of travel is still level to earth. 3. If any deviations exist, they need to be corrected at this time. If the deviations are very small, the mating flange of the two bases does not need to be unscrewed. If the deviations are very large, attempting to correct the level may induce a large stress in the assembly that will not allow earth level to be fully achieved. It is important for the geometry of the machine that earth level be achieved. The table at center of travel is now known to be at earth level and the column base is also at earth level. The process of extending that level over the travel of the X-axis may now begin by starting to load the remainder of the leveling screws. 4. Lower the remainder of the table base leveling screws to touch off on the leveling pads below. 5. Move the table toward zero so the levels are in line with the next set of leveling screws after the primary leveling screws. Make a very slight correction to the leveling screws at that location if the level deviates from zero.
NOTE: Attempting to compensate for all of the deviation at any single position may compound an otherwise small error. Do not try to final level the table base in a single pass over the travel of the X-axis.

6. Continue moving the table toward zero, stopping at each instance where the levels are in line with the leveling screws. Make small adjustments that begin to correct the deviation from earth level. When the end of travel is reached, the leveling screws on the end of the table base can be slightly adjusted. 7. Return the table to the center of travel. Verify that earth level still applies to the table at that position. If it does not, it must be attained again before continuing. Only the leveling screws that have been previously adjusted should be used. Do not alter the position of the four primary leveling screws at this time. 8. Move the table in the same increments as before but in the direction away from zero. Repeat the very slight adjustment procedure, beginning to make a correction in the table, level to earth. 9. Move the table back to the center of travel and verify that the primary earth zero has not been affected. If earth zero does not exist at the center of travel, make the correction now. The load of the table base assembly is now being shared over all of the leveling screws. The table at the center of travel is at earth zero, and the column base is at earth zero.

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Fine Leveling of the Table Base


Using the same process as loading the leveling screws in the previous steps, move the table over to line up the levels with the leveling screws and begin to make very moderate adjustments toward earth zero. Continue the process to the end of travel as before, then return to the center of travel and verify earth zero there. Move from the center of travel the other direction and repeat the procedure until the table is at earth zero over the entire travel of the X-axis. Verify that the Y-axis has not been affected by the leveling procedure of the X-axis. If it has, use the steps described previously to make the necessary correction and then verify that the X-axis is still correct. Do not try to hurry this process. This is a careful, repetitive, process that relies on modest adjustments for each step along the way. If too large an adjustment is attempted, the geometry will fail and it may not be possible to determine the corrective action and the bases may have to be disconnected to rectify the situation. When fine leveling is completed, tighten the jam nuts on the leveling screws.

Sweeping the Table


The sweep of the table should be little more than a verification of the leveling process. Using the special tool for mounting the indicator, first verify that the table is within specification as the Y-axis is moved. Then, for several Y-axis positions where the indicator is on the table surface, run the X-axis from end to end and verify that it is also within specification.

Geometry Check
The final step of the leveling and squaring process is to verify the overall machine geometry with respect to the individual geometric inspection report of the machine. Every point of inspection must be verified to be within the tolerances specified for the machine.

Completing the Installation


1. Replace all sheet metal removed paying particular attention to sealing any component mating surface potentially exposed to coolant flow. 2. Install the table gutter fence. 3. Install and verify operation of the tool changer (see the section on tool changer installation and alignment for the specific toolchanger). Verify all machine functions.
Cable Support Clamp Cable
X-A xis

X-Axis Auger Trough Cable (To X-Axis Auger Motor)

Cable X-Axis Auger Trough

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SPINDLE SWEEP
NOTE: The machine must be properly leveled for the spindle sweep adjustment to be accurate; no more than .0002 twist on the Y-axis (vert mill).

1. To check spindle sweep, place a .0005 indicator on a suitable holder, place on spindle nose and jog the Zaxis in the negative (-) direction enough so that you can adjust the indicator to sweep a 5" radius from the center of X- and Y-axis travel. Slowly jog Z-axis in the negative (-) direction to zero out indicator. 2. Establish a reference point (indicator zero), sweep the three remaining points and record the reading.

10" dia. circle

Spindle Sweep Area

COOLANT TANK INSTALLATION


1. The coolant pump(s) is packed inside the machine enclosure for shipping. 2. Remove the handle from the underside of the coolant tank lid. Use the same hardware (screws) to secure the handle to the coolant tank.
NOTE: Do not fill the coolant tank before removing the handle from under the lid.

3. Orient the pump(s) and lower into the coolant tank as shown. Place supplied cover(s) as shown. When not using a TSC pump, install the large cover in place of the two small covers (see illustration). 4. Position the coolant tank under the left side of the machine.
To TSC Filter TSC Pump Assembly (If supplied) Handle

Cover 2 (With no TSC) Coolant Tank

Standard Pump Assembly Cover 1 Lid

55-Gallon Coolant Tank Shown NOTE: It is important that the coolant tank is in place before leveling the machine to ensure there is adequate clearance between the bottom of the discharge tube and the tank.

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5. The Coolant Level Float Assembly is shipped in a separate box. It consists of a housing, float and cable. Install the Coolant Level Float Assembly by lowering the float through the tank lid, line up the slots in the housing with the dimples on the side of the tank and press down so the float assembly clips onto the tank. 95-Gallon coolant tank - The float can be mounted on either the edge of the coolant tank or the center.
Housing Housing

Dimples Float Dimples

6. Insert a plastic push wire mount into the hole in the tank lid, then route the cable to the coolant pump(s). Tie wrap the coolant float cable to other cables, when available, when routing from the coolant tank (see figure).

55 Gallon tank shown

7. Connect the cable to the Coolant Level Gauge (CLG for VF 1-5 machines) plug. Locations: VF 1-5: CLG on left side of control cabinet. VF 6-11, VR: Sheet metal on lower back of column. VS: Bulkhead on back of X-axis table. MDC: Rear sheet metal below tool changer. 8. Select the Current Commands screen on the operator's pendant and move the float up and down to ensure that the display reflects a corresponding change in the coolant level.. 9. Connect the main coolant line (3/4" O.D.) to the main pump. Connect the main pump power line to the outlet on the right side of the electrical panel. 10. If machine includes Through the Spindle Coolant option (TSC), attach the 3/4" (for VF/VM Series) or 1/2 ( for VR and VS series) O.D. coolant line to the TSC pump. NOTE: The TSC power line is hard-wired to the main pump power line. 11. Route the coolant/oil separator return hose to the coolant tank. The coolant return hose must slope downward to the coolant tank. When installing the coolant return hose, pour a cup of coolant through the return hose to charge the unit. 12. Fill coolant tank with water-based coolant only. Do not use mineral cutting oils, they will damage rubber components throughout the machine and void the warranty.
NOTE: Before operating the coolant system, ensure the drain is positioned halfway over tank strainer.

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A UXILIARY F ILTER

Standard Coolant Systems

Filter Inlet Hose Pressure Gauges Auxiliary Filter Assembly Standard Coolant Pump

Drain Back Hose Coolant Hose From Machine


VF Series Machines Shown

Installation
1. Place the Auxiliary Filter system next to the coolant tank of the machine. 2. Connect the output of the Standard Coolant pump to the input of the Auxiliary Filter. 3. Connect the Auxiliary Filter output hose to the coolant hose of the machine. 4. The Auxiliary Filter tank must be filled with coolant before use. 5. To fill the Auxiliary Filter tank from the Standard Coolant tank, perform the following steps: Turn on the Standard Coolant Pump. Open the ball valve, located on the top of the Auxiliary Filter tank. Wait for coolant to appear in the drain-back hose. Close the ball valve; the Auxiliary Filter tank is full.

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Optional Auxiliary Filter for TSC System

TSC Filter Assembly 100 Micron Primary Coolant Pump

Intake Filter Assembly

TSC Coolant Pump Assembly

Dirt Indicator

Auxiliary Filter Assembly


Optional Auxiliary Filter setup

Standard Filtration Setup

Installation
1. Place the filter assembly approximately six inches behind the coolant tank, for tanks that pull out from the side. For tanks that pull out from the rear of the machine, place the Auxiliary Filter beside the coolant tank next to the enclosure. 2. Remove the 100 mesh strainer from inside of the TSC intake filter. Attach the hose from the top of the TSC intake filter to the hose connector on the Auxiliary filter. For large vertical machines, remove the original hose from the intake filter and replace with the longer hose included in the kit. Secure it to the hose barb using the supplied hose clamp. The hose may be trimmed shorter if desired for appearance. 3. Disconnect the 1/2" check valve from the 45 elbow at the base of the normal coolant pump. Install the 1/2" street-tee from the kit between the 45 elbow and the check valve. Install the pipe reducer from the kit into the side outlet of the street-tee. Install the 1/4" push-in elbow into the pipe reducer. (See the Figure below.) For coolant pumps supplied with a cross fitting, remove one of the plugs and install the reducer into the cross fitting. The street tee will then not be used.
NOTE: The check valve cap should point up for the check valve to function properly.

Cable Tie Filter Outlet 1/4" O.D. Plastic 1/4 O.D. Plastic Hose Reducer Push-in Check Valve

Push-in Hose Elbow

Auxiliary Filter Assembly Elbow

45 Elbow

Auxiliary Filter Priming System

4. Insert the 1/4" OD plastic hose into the push-in elbow on the pump. Route this hose along the filter intake hose and follow the intake line of the auxiliary filter. Trim the hose to length and insert into the push-in elbow on top of the filter. Secure the plastic hose to the inlet hose using the supplied cable ties (See the figure). 5. Attach the hose from the bottom of the Auxiliary Filter to the inlet of the TSC gear pump. 6. Check that the filter lid is securely closed and clamped. 7. Run the primary coolant system for ten minutes to prime the bag filter housing before using the TSC system.

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C HIP A UGER I NSTALLATION


1. Unpack the auger and discharge tube.
Motor Hub

Set Screw

Auger

2. Slide the auger into the discharge tube opening and then slip the opposite end onto the motor hub. Fasten it to the motor hub with the 5/16-18 x 2" bolt. 3. Install the gasket and slide the discharge tube up and onto the studs. Attach the eight nuts with locking washers and tighten uniformly. 4. After machine start-up, check auager operation to ensure the direction of rotation will move the chips toward the discharge tube. If the auger is turning so that the chips are not being moved toward the discharge tube, change the bit switch in REV CONVEYOR from 1 to 0 or 0 to 1 to establish a new forward direction.

M INIMAL O ILING M ACHINING (MOM) O PTION


The MOM cable carrier is wrapped and shipped inside the machine. This cable carrier protects the oil tubing as it is routed to the injector nozzle. It must be installed before using the machine.

Snaps over bracket stud

Cable Carrier Zipper

Cable Carrier

Cable Carrier Bracket Hose Cover Snaps inside bracket

Cable Carrier Bracket


0

Bracket Oil Tubing

1. The MOM oil tubing is tie-wrapped to the top enclosure cover for shipment; cut the ties. Remove the cable carrier from its packaging and remove the zipper. 2. Attach the cable carrier to the two brackets on the top of the machine. Route the oil tubing along the trough in the cable carrier. 3. Snap the zipper into place on the cable carrier, covering the oil tubing. Ensure that the zipper snaps securely into place on both sides of the carrier. 4. Test the installation by exercising the Z-axis for approximately 5 minutes to ensure smooth operation.

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PENDANT LEVELING
On VF1/5 machines, make sure hinge screw is installed and tight before leveling the pendant.

The pendant leveling feature allows the angle of the pendant to be adjusted during installation.
1. Rotate the pendant as shown for proper leveling.
Loosen These Two Screws, Leveling Before Adjusting Leveling Screw Screw.
Leveling Monitor Screw

Leveling Screw

Hard Stop VF-5 Top View VF-3/4

VF-1/2

2. Loosen the two (2) screws on the end cap before adjusting the leveling screw. 3. Use a wrench on the leveling screw to change the angle of the pendant. 4. Tighten the two (2) screws on the end cap once the pendant is level. 5. Rotate the pendant 90 forward and check the level again. Repeat the procedure if necessary.

H IGH INTENSITY LIGHTING


To properly orient the High Intensity Lighting on a VF-6/10, perform the following procedure. For shipping purposes, the right High Intensity Light assembly has been rotated 180 as shown:

Shipping Position

Operating Position

After the machine is installed, the High Intensity Lighting option must be reconfigured from its shipping position. To do this, perform the following steps on the right light assembly. 1. Remove the BHCS securing the cover to the light arm. Remove the cover. 2. Remove the two BHCS securing the High Intensity Light assembly to the header bar. Loosen (but do not remove) the center pivot screw. Remove the two BHCS from the threaded holes in the header bar. Rotate the light assembly 180 and line up the holes in the light assembly with the threaded holes in the header bar. Insert the removed BHCS and tighten all five screws.

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Secure Bracket using these 5 screws

FRONT

Pivot Screw (loosen only) Remove 4 screws TOP VIEW OF MACHINE (Temporary shipping configuration)

FRONT

TOP VIEW OF MACHINE (Setup Complete)

3. Take up any slack in the power cables. Tighten the strain-relief nuts. 4. Attach the High Intensity Light cover to the back of the light assembly and secure with screws removed in step 1.

ACCESSORY TABLE
The Accessory Table is wrapped and shipped in the machine. Unwrap and install the table in the provided mounting brackets on the front of the machine.

C RANE A RM I NSTALLATION
NOTE: The Crane Arm is optional on VF 6-11 machines. Crane Arm is secured to the pallet, under the machine. Do not discard the pallet or packing material until the crane arm has been removed.

Important:

CAP. 1000lbs./

450kg MAX.

POWERON POWEROFF

SPINDLE LOAD
O 50 100 150 180

20HP

DUAL DRIVE

VECTOR
EMERGENCY STOP

HANDLE

0 0
90
10
20 80

90

10

80
20

70

70 30

30

CYCLE START FEEDHOLD

Crane Arm

Installation Procedure
1. Remove the Crane Arm from the shipping base.

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40

50 50

40

60

39

2. Lift the Crane Arm into position. There is a hole in the Crane Arm specifically for lifting. 3. Secure the Crane Arm to the right side of the column using the four (4) bolts and washers provided. Make sure all of the cables are guided through the opening on the crane between the mounting bolts. Do not allow them to become pinched between the Crane Arm and the column when mounting.
NOTE: The Crane Arm capacity is 1000 lbs, and does not include lift chain device or trolley.

THROUGH THE SPINDLE C OOLANT SYSTEM STARTUP


WARNING!
THE THROUGH THE SPINDLE COOLANT (TSC) PUMP IS A THREE-PHASE PUMP AND MUST BE PHASED CORRECTLY! IMPROPER PHASING WILL DAMAGE TO THE TSC PUMP AND VOID THE WARRANTY.

1. Fill the coolant tank with coolant and connect all hoses and power cords. Zero Return the machine. 2. Switch to MDI. Turn on TSC by pressing the AUX CLNT button on the control panel. Quickly go to the back of the machine and check if the TSC pump motor is turning. Check if the pump is pulling coolant up the clear intake hose. If it is, the machine is properly phased. If it is not pumping coolant, immediately stop the pump by pressing the RESET button. Check that the intake hose connection is tight. The pump cannot prime itself if the intake hose is loose. If the motor is not turning, check that the power cords are connected and the circuit breaker inside the control box is on. The TSC pump will not pump if it is rotating backwards. The motor rotation should be counterclockwise when viewed from the fan end. If the motor is not rotating, or rotating in the correct direction, but the pump is not pumping, call your Haas Service Technician.
CAUTION! Running the TSC pump dry for more than 60 seconds can cause serious damage to the pump.

3. If the machine is improperly phased perform the following procedure: a. Make sure there is no power at the input side (top) of the main circuit breaker. MEASURE THE VOLTAGE! b. Exchange any two wires at the input side (top) of the main circuit breaker as shown:

Ground Line
L1 L2 L3

Main Circuit Breaker

c. Close the control box. d. Return to Step 1 and test for proper phasing.

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1000 P SI T HROUGH THE S PINDLE C OOLANT I NSTALLATION


Place the 1000psi TSC assembly next to the coolant tank behind the machine with the hose connections facing the back of the machine. Use the following coolant schematic as an aid for hose routing. 1. Connect the power cable for the pump assembly to an external source in order to power the motor. Note, that the CNC control does not provide power to the pump motor. Customer supplied external power must be supplied at the time of installation. The power required is 208-230 volt 3-phase 50/60Hz, and have a 20-amp circuit breaker. The pump assembly is pre-wired with a NEMA L15-20 plug. The pump assembly can also use an alternate power source, these are: 240-230V 50/60HZ @ 20A 480V 50/60HZ @ 10A To power the pump assembly from an alternate source, first replace the plug at the end of the cable with an appropriate plug for the voltage being used. Then, rewire the pump motor according to the directions on the side of the motor. 2. Plug the TSC cable from the TSC junction box (J-box) to the TSC amphenol port on the side of the control cabinet. 3. Connect the 1" diameter intake hose from the coolant tank to the nipple on the pressure regulator bracket. 4. Attach the 1/2" diameter bypass hose from the coolant tank, to the pressure regulator bypass. 5. Insert the 1/4" diameter nylon tubing from the standard coolant motor into the push in tube fitting on the pressure regulator bracket. 6. Connect the TSC hose from the mill to the pressure regulator output fitting.
CC CIA MTR CP GA AF P/AFA PA CC RA MTR GA INTAKE HOSE CP COOLANT TANK COOLANT INTAKE ASSEMBLY STANDARD COOLANT MOTOR COVER PLATE SUCTION GAGE, INTAKE FILTER AF TANK ASSEMBLY COOLANT PUMP & TANK ASSEMBLY COOLANT PUMP CONTROL CABINET PRESSURE REGULATOR

TSC

TSC CABLE FROM J-BOX P/AFA PA AF PRIMING CIA TUBE

TO MACHINE

RA

COOLANT FLOW

BYPASS HOSE TO COOLANT TANK

Regulator Jam Nut

Pressure Regulator Adjusting Bolt Filter Priming Hose Discharge Hose

Oil Reservoir

Bypass Hose

Bypass Hose

Intake Hose

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I NITIAL S TART-U P

Ensure that a correct style tool is in place; a proper tool and pull stud for TSC.
Before using the 1000psi system the auxiliary filter must be primed. There are two ways to do this. The first is to run the standard coolant pump for 5 minutes. This will fill the auxiliary tank, through the priming hose. The second method is to attach the wash down hose to the standard coolant pump. Turn on the standard coolant system (press "MDI", then "Coolant"). It may be necessary to turn the valve(s) on the standard coolant pump to in order to divert coolant to the hose. Open the auxiliary filter tank cover (loosen wing nuts) and use the wash down hose to fill the auxiliary filter with coolant. Replace the auxiliary tank cover and tighten securely.
NOTE: To reduce wear and prolong the life of the auxiliary filter, the 1/4" nylon hose is connected between the standard coolant pump and the auxiliary filter which will maintain the coolant level in the filter tank.

PRESSURE REGULATOR ADJUSTMENT


The pressure regulator has been set at 1000psi and tested at the factory. No further adjustment is required. However, to change the pressure, loosen the regulator jam nut. Turn the adjusting bolt clockwise to increase the pressure or counter clockwise to decrease the pressure. (Note, the system does not need to be on to change pressure) Tighten the regulator nut once the pressure has been set.

R EPLACEMENT OF F ILTER B AGS


Change the filter bag when the filter gauge indicator displays a vacuum level of -5 in. Hg or more. Do not allow the suction to exceed -10 in. Hg or pump damage may occur. HAAS recommends using 25-micron rated filter bags. Replacement bags can be purchased from local filter suppliers or from HAAS (Part No. 93-9130). Finer micron rating bags can be used.

MAINTENANCE
Before doing any maintenance to the 1000psi system, disconnect the power source; unplug it from the power supply. Check the oil level on a daily basis. If the oil is low, add oil through the fill cap on the reservoir. Fill the reservoir about 25% full with 10-30W oil.

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WASHDOWN HOSE INSTALLATION


The Tote Kit supplied contains a Washdown Hose Kit. This includes one Hose, one Nozzle, two (2) Hose Washers, and one Y connector. The nozzle should have a washer tied on to the handle. 1. Detach the washer from the nozzle handle, and insert it into the connecting end of the nozzle. 2. Insert one of the hose washers in the female end of the hose. The other washer is a spare. 3. Attach the nozzle to the male end of the hose. 4. Detach the P-cool hose from the coolant pump. 5. Attach the Y connector to the coolant pump where the P-cool hose was. 6. Attach the P-cool hose to one of the Y outlets and the Washdown hose to the other.
Washdown Hose

P-Cool hose Y-Connector

S ERVO C ONTROL BRACKET INSTALLATION (OPTIONAL )


1. Remove tool holder bracket from pendant shelf. 2. Use the tool holder bracket screws to attach the Servo Control bracket to front pemnuts of the pendant shelf. Use a scribe to mark the location of the two holes to drill. Remove the bracket and drill two (0.25) holes through the pendant shelf in the middle of the scribed circles. Reinstall the Servo Control pendant bracket to pendant shelf using four 10-32 X 3/8 button head cap screws. 3. Attach the tool holder bracket to the Servo Control pendant bracket with the remaining screws. 4. Remove rear servo control rubber feet and screws. Slide servo control into the bracket from the back. Position the control so the rear baseplate threaded holes line up with the holes in the bracket. Reinstall the screws into the servo control baseplate, through the bracket, without the rubber feet. 5. Mount the table or indexer to the mill table. Route the cables over the mill sheet metal enclosure. Make sure the cables do not limit the table travels. Attach the cables to the control box; control must be powered off.

Brushle Rotary ss Control

SERVO ON

STEP

RUNNIN G

CYCLE START

EMERGE

NCY

DEGRE ES

OVER LOAD

STOP

HIGH LOAD

JOG

+
9

ZERO RETURN

CLEAR ZERO SET

7 8 9 4 5 6 1 2 3 0 -

MODE RUN PROG DISPLAY SCAN

STEP SCAN

10-32X3/8 BHCS Locations


Installed Servo Control Bracket

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SPINDLE RUN-IN
CAUTION! The spindle run-in program must be run before the spindle can be run above 1000 rpm. Failure to run this program can result in spindle over heating and failure.

Before running the spindle, a spindle run-in must be performed. A program has been supplied with the machine which will slowly run the spindle up to speed (approx. 2 hrs). This will purge out any oil which may have settled at the nose of the spindle due to long idle time. The program is # O02021 Spindle Run-In and will be used for all spindle types and rpms. Adjust spindle speed override depending on maximum spindle speed of the machine: Set override at 50% for 5,000 RPM machines; at 100% for 7,500 and 10,000 rpm machines; and at 150% for 15,000 rpm machines. For machines equipped with a 50 taper spindle, run spindle speed override at 50%. N100 S750M3 G04 P600.; S2500M3; G04 P600.; S5000M3; G04 P900.; N200 M97 P1000 L15 M97 P2000 L15 M30; N1000 S7500M3; G04 P30.; S500 M3; G04 P150.; M99; N2000 S10000M3; G04 P30.; S500M3; G04 P150.; M99; %

The HSK 63A Faemat spindle requires a toolholder in the spindle and the chiller to be set at 20C while the spindle is running. The spindle should be checked periodically for spindle temperature rise. If the temperature rises above 150F, start the program from the beginning. If the temperature rises above 150F again, contact your dealer.

SPINDLE WARM-UP P ROGRAM


All spindles, which have been idle for more than 4 days, must be thermally cycled prior to operation above 6,000 RPM. This will prevent possible overheating of the spindle due to settling of lubrication. A 20-minute warm-up program has been supplied with the machine, which will bring the spindle up to speed slowly and allow the spindle to thermally stabilize. This program may also be used daily for spindle warm-up prior to highspeed use. The program number is O02020 (Spindle Warm-Up). O02020 (Spindle Warm-Up) S500M3; G04 P200.; S1000M3; G04 P200.; S2500M3; G04 P200.; S5000M3; G04 P200.; S7500M3; G04 P200.; S10000M3; G04 P200.; M30;

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